Heat exchanger systems

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Solution Overview

Problem

Heat pump systems face inefficiencies at low ambient temperatures, struggling to maintain effective operation below -30 degrees Fahrenheit, as existing technologies fail to optimize refrigerant prewarming and heat exchange processes.

Innovation Solution

The implementation of a suction superheater and desuperheater system that modulates fluid flow to prewarm refrigerant before the compressor, using a heat optimization system with a tank design and coiled heating/cooling lines to enhance heat exchange, and a controller to manage fluid flow and temperature modulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional heat pump system operates at low ambient temperatures, then the system maintains basic heating function, but the operating efficiency deteriorates significantly below -30 degrees Fahrenheit

Engineering Contradiction:

Improveoperating efficiencyVSAvoidambient temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The suction superheater preheats the refrigerant before it enters the compressor, preparing the refrigerant in advance for optimal compression. This preliminary heating action ensures the refrigerant is at the correct temperature and pressure state before compression, maintaining system efficiency even in extremely cold ambient conditions below -30°F.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts refrigerant temperature, pressure, and flow rate parameters through the superheater and desuperheater components. By changing these thermodynamic parameters of the refrigerant based on ambient temperature conditions, the system optimizes heat exchange efficiency and maintains reliable operation across a wide temperature range.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If refrigerant is not prewarmed before the compressor, then the system structure remains simple, but heat exchange efficiency deteriorates at low temperatures

Engineering Contradiction:

Improveheat exchange efficiencyVSAvoidsystem structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The heating and cooling coils are nested within the refrigerant flow path, with coils positioned inside the tank structure. This nested arrangement allows multiple heat exchange functions to be integrated within a compact volume, improving heat transfer efficiency without proportionally increasing system complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The suction superheater acts as an intermediary component between the refrigerant source and the compressor. It mediates the temperature and pressure of the refrigerant, ensuring optimal conditions for compression and heat exchange, thereby improving overall system efficiency despite the added component.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If fluid flow is not modulated through the superheater, then the system operation remains simple, but temperature control precision deteriorates

Engineering Contradiction:

Improvetemperature control precisionVSAvoidfluid flow modulation

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The controller monitors refrigerant temperature and flow conditions, then dynamically modulates the fluid flow through the superheater coils based on feedback signals. This closed-loop control ensures precise temperature regulation of the refrigerant, maintaining optimal operating conditions despite variations in ambient temperature and system load.

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution improves the operating efficiency of heat pump systems at low temperatures by effectively warming refrigerant, enhancing heat exchange, and optimizing fluid flow, thereby maintaining performance even at -30 degrees Fahrenheit.

Implementation Method 1

the heating line may be configured to receive a heated fluid from an external heat source... the heating line increases the temperature of the input refrigerant

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

a secondary heated fluid to a suction superheater downstream of a compressor that warms the primary recirculating refrigerant via a heat exchange process

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS11566823B1Heat exchanger systems

Publication Date: 2023.01.31 FERIA RALPH

AI summary

Heating and cooling optimization systems are disclosed. Such systems may include a superheater and desuperheater are disclosed. An example superheater may include a combined suction line accumulator and heat exchanger configured to receive a heated fluid from an external source. An example desuperheater may comprise an accumulation tank and a heat exchanger configured to receive a relatively cool fluid from an external source. Various external sources may be a solar thermal source, a wood chip boiler, a ground loop, a geothermal source, an attic space, a garage, and/or a chemical heat source. Disclosed heating and cooling systems may include a controller sub-system for selectively modulating a flow rate of heated fluid through the superheater and for selectively modulating a flow rate of cooled fluid through the desuperheater.